Cleat assembly for clipless bicycle pedal

ABSTRACT

An improved cleat assembly configured to be releasably secured to a clipless bicycle pedal comprises a first plate, a second plate disposed over the first plate, and plurality of spacers disposed between the first and second plates, the spacer separating the first and second plates a predetermined distance. The second plate may define a pedal aperture having a circumferential periphery comprising a first portion and a side tie portion and the side tie portion may be offset from the first portion. The cleat assembly may further comprise a cap disposed over at least the second plate wherein the second plate may comprise a first of an engagement pair and the cap may comprise a second of the engagement pair. The first and second of the engagement pair may cooperate to couple the cap and the second plate to affix the cap onto the cleat assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/006,873 filed Aug. 30, 2020, which is a continuation of U.S. patentapplication Ser. No. 16/236,199 (now U.S. Pat. No. 10,759,491) filedDec. 28, 2018, which is a continuation of U.S. patent application Ser.No. 14/475,248 (now U.S. Pat. No. 10,279,862) filed Sep. 2, 2014. Theentire disclosures of the applications referenced above are incorporatedby reference.

FIELD

The present invention relates generally to cleat assemblies configuredfor releasable securement to pedals for bicycles and the like, and, moreparticularly, to clipless bicycle cleat assemblies having improveddurability, operation, and feel.

BACKGROUND

Footwear-mounted engagement methods have been used in cycling, skiing,snowboarding, rowing, and numerous other sports, to attach a user to adevice for increased power and/or control.

Engagement of footwear-mounted cleats or cleat assemblies to bicyclepedals, in particular, have been notoriously difficult for a number ofreasons. The cleat is mounted to the underside of a rider's shoe soleand is thus hidden from view. Likewise, the pedal assembly, beingmounted to the underside of the rider's shoe sole, is also obscured fromview by the shoe during the engagement process. Thus, engagement of arider's shoe to a pedal assembly requires the rider to blindly align orengage the cleat to the pedal, relying primarily on tactile feedback andmost typically while the rider is still in motion.

The tactile feedback experienced during engagement and disengagement ofcleat assemblies to a pedal may change over time and use. Cleatassemblies are typically subjected to significant wear and tear duringuse and also when the user is simply walking around, as, the bottom mostsurface of the cleat assembly necessarily makes direct contact with theground. Moreover, cleat assemblies may include multiple parts, typicallymade from various different materials having different materialproperties, which are coupled together. Over time and use, the materialproperties may change to alter the tactile feedback of the cleatassembly during engagement with and disengagement from the pedal.

SUMMARY

It is desirable for bicycle cleat assemblies to substantially withstandthe physical rigors during use and when the user is simply walking. Ascleat assemblies are often constructed of multiple parts comprisingvarious different materials exhibiting different physicalcharacteristics such as strength, stiffness, elasticity, plasticity,ductility, malleability, hardness, brittleness, etc., it is importantthat the cleat assemblies do not change significantly so as tomaterially change the tactile feel during engagement with anddisengagement from the bicycle pedal.

For example, it is preferable that the various parts that comprise abicycle cleat assembly remain securely coupled to one another, such asby way of bolted joints, in order to reduce or eliminate sloppy feel,particularly while the bicycle cleat assembly is releasably secured to abicycle pedal and during the pedal engagement and disengagement process.Tightening attachment screws will apply varying degrees of clampingforce to any intervening components of the bolted joints of the bicyclecleat assembly. If intervening components in a bolted joint comprise adeformable material (i.e., elastomeric materials, plastic, and othersimilar types of materials), repeated tightening of the attachmentscrews may be required because the aforementioned intervening componentscan deform over time in response to the resulting clamping force. Theintermediate plate can also comprise a substantially non-deformablematerial such as metal alloy or a combination of deformable andnon-deformable materials.

In one embodiment, a cleat assembly configured to be releasably securedto a clipless bicycle pedal is described. The cleat assembly comprises afirst plate, a second plate shaped to be disposed over the first plate,and a plurality of spacers configured to be disposed between the firstand second plates. The second plate defines a first pedal aperture andcan be constructed from various materials or even combinations ofmaterials such as metal or carbon fiber. The plurality of spacers eachcomprise a substantially non-deformable material and having a height tospace apart the first and second plates at a predetermined distance whenthe plurality of spacers are disposed between the first and secondplates. In one embodiment, the predetermined distance is substantiallyequivalent to the height of the spacers.

In accordance with a first aspect, the plurality of spacers are formedon either one or both of the first and second plates.

In accordance with a second aspect, the plurality of spacers are formedon the second plate.

In accordance with a third aspect, the plurality of spacers eachcomprises a base end, a terminal end, a side wall that tapers from thebase end to the terminal end, and a bore through the base and terminalends.

In accordance with a fourth aspect, the second plate further comprises afirst flange disposed around at least a portion of the pedal aperture.The first flange comprises at least one opening in communication withthe bore of at least one of the plurality of spacers.

In accordance with a fifth aspect, the cleat assembly further comprisesan intermediate plate disposed between the first and second plates. Theintermediate plate can be made of a deformable material such as plasticor a substantially non-deformable material such as metal alloy.

In accordance with a sixth aspect, the intermediate plate comprises abody and a second flange disposed around at least a portion of the body.The body defines a second pedal aperture. The second flange comprises atleast one bore sized and configured to allow at least one of theplurality of spacers to pass through.

In accordance with a seventh aspect, at least a portion of the body ofthe intermediate plate is thicker than the second flange of theintermediate plate.

In accordance with an eighth aspect, the cleat assembly furthercomprises a cap disposed over at least a portion of the second plate.

In another embodiment, a cleat assembly configured to be releasablysecured to a clipless bicycle pedal is described. The cleat assemblycomprises a first plate and a second plate disposed over the firstplate. The second plate defines a first pedal aperture having acircumferential periphery. The circumferential periphery comprises afirst portion defining a first plane, and a side tie portion.

In accordance with a first aspect, the side tie portion is offset fromthe first plane.

In accordance with a second aspect, the first portion is in greaterspaced relation to the first plate than the side tie portion.

In accordance with a third aspect, the cleat assembly further comprisesan intermediate plate disposed between the first and second plates.Preferably, the intermediate plate comprises a body and a second flangedisposed around at least a portion of the body. The thickness of atleast a portion of the body of the intermediate plate is greater thanthe thickness of the second flange of the intermediate plate.

In accordance with a fourth aspect, the cleat assembly further comprisesa plurality of spacers formed from the second plate and disposed betweenthe first and second plates. The plurality of spacers each comprise asubstantially non-deformable material and have a height to space apartthe first and second plates at a predetermined distance. In a preferredembodiment, the predetermined distance is substantially equivalent tothe height of the spacers. The plurality of spacers each comprises abase end, a terminal end, a side wall that tapers from the base end tothe terminal end, and a bore through the base and terminal ends.

In accordance with a fifth aspect, the second plate further comprises afirst flange disposed around at least a portion of the first pedalaperture. The first flange comprises at least one opening incommunication with the bore of at least one of the spacers to receive atleast one screw for securing the second plate and the first plate. Thesecond flange of the intermediate plate comprises at least one boresized and configured to allow at least one of the spacers to passthrough.

In accordance with a sixth aspect, the cleat assembly further comprisesa cap disposed over at least a portion of the second plate.

In a further embodiment, a cleat assembly configured to be releasablysecured to a clipless bicycle pedal is provided. The cleat assemblycomprises a first plate and a second plate disposed over the firstplate. The second plate defines a first pedal aperture and comprises aperipheral edge having a first of an engagement pair. A cap comprises anexternal surface and an internal cavity. The cap is configured to housethe second plate within the internal cavity, the cap comprising a secondof the engagement pair. The first and second of the engagement pairremovably couples the cap and the second plate. The first of theengagement pair comprises one of a plurality of grooves or a pluralityof tongues. The second of the engagement pair comprises the other of theplurality of grooves or the plurality of tongues. These first and secondengagement pairs provide more secure coupling and allow the cap tobetter resist accidental disengagement from the second plate while theuser is walking about on the ground (e.g., due to twisting or pivotingof the user's foot).

In accordance with a first aspect, the cleat assembly further comprisesa plurality of spacers formed on the second plate and is configured tobe disposed between the first and second plates. The spacers eachpreferably comprises a substantially non-deformable material and has aheight to space apart the first and second plates at a predetermineddistance. An intermediate plate is disposed between the first and secondplates, the intermediate plate having a body defining a second pedalaperture and a second flange disposed around at least a portion of thesecond pedal aperture. The second flange comprises at least one boresized and configured to allow at least one of the plurality of spacersdisposed between the first and second plates to pass through. At least aportion of the body of the intermediate plate is thicker than the secondflange of the intermediate plate. The second plate further comprises afirst flange disposed around at least a portion of the first pedalaperture, the first flange comprising at least one opening incommunication with the bore of the plurality of spacers to receive atleast one screw for securing the second plate and the first plate. Theplurality of spacers comprise a base end, a terminal end, aside wallthat tapers from the base end to the terminal end, and a bore throughthe base and terminal ends.

In accordance with a second aspect, the first pedal aperture of thesecond plate comprises a circumferential periphery comprising a firstportion defining a first plane and a side tie portion. The side tieportion is offset from the first plane and wherein the first portion isin greater spaced relation to the first plate than the side tie portion.

Other features and advantages of the present invention should becomeapparent from the following description of the preferred embodiments,taken in conjunction with the accompanying drawings, which illustrate,by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of the first plate of an embodiment of thecleat assembly in accordance with the invention.

FIG. 2 is a top plan view of the first plate and the intermediate plateof an embodiment of the cleat assembly in accordance with the invention.

FIG. 3 is a top plan view of the first plate, the intermediate plate,and the second plate of an embodiment of the cleat assembly inaccordance with the invention.

FIG. 4A is an exploded side elevational view of the first plate, theintermediate plate, the second plate of an embodiment of a cleatassembly in accordance with the invention.

FIG. 4B is an exploded side elevational view of the three plates of theembodiment of the cleat assembly depicted in FIG. 1 , the plates beingrotated clockwise 90°.

FIG. 5 is a top plan view of the first plate, the intermediate plate,the second plate, and the elastomeric cap of an embodiment of the cleatassembly in accordance with the invention.

FIG. 6 is a perspective view of the topside of the second plate of anembodiment of the cleat assembly in accordance with the invention.

FIG. 7 is a perspective view of the second plate and the elastomeric capof an embodiment of the cleat assembly in accordance with the invention.

FIG. 8A is a side elevational view of the first plate of an embodimentof the cleat assembly in accordance with the invention.

FIG. 8B is a close-up cross sectional view of a portion of the secondplate and a portion of the intermediate plate of an embodiment of thecleat assembly in accordance with the invention.

FIG. 8C is a side elevational view of the second plate coupled to thefirst plate of an embodiment of the cleat assembly in accordance withthe invention.

FIG. 8D is a perspective view of the underside of the second plate of anembodiment of the cleat assembly in accordance with the invention.

FIG. 9 is perspective view of the underside of the intermediate plateand the second plate of an embodiment of the cleat assembly inaccordance with the invention.

FIG. 10 is a top plan view of an embodiment of a clipless bicycle pedalwith which the cleat assembly can be used.

DETAILED DESCRIPTION

With reference now to the illustrative drawings, and particularly toFIGS. 1-3 , there is shown an embodiment of a cleat assembly 10 inaccordance with the invention, configured for attachment to the sole ofa user's shoe (not shown) and for releasable securement to a bicyclepedal 60 (FIG. 10 ). The particular cleat assembly depicted isconfigured for attachment to the user's left shoe, but it will beappreciated that a similar cleat assembly could be oppositely configuredfor attachment to the user's right shoe. The clipless bicycle cleatassembly includes a first plate 12, an intermediate plate 16, and asecond plate 20. The first plate is configured to be secured to theshoe's sole (not shown) by screws 14 extending through three elongatedopenings 15. In one embodiment, the first and intermediate plates aremade of plastic and the second plate is made of a metallic material.

More particularly, as illustrated in FIGS. 4A and 4B, the intermediateplate 16 and second plate 20, together, are configured to be secured tothe first plate 12. A spring clip 18 is mounted between the intermediateplate and the second plate (see also FIGS. 2, 3 ), for releasablyengaging the pedal when the cleat assembly is positioned over thebicycle pedal 60 (FIG. 10 ). It should be noted that engagementmechanisms other than a spring clip can be used to releasably engage thecleat assembly to the pedal.

With reference now to FIG. 5 , there is shown an embodiment of aclipless bicycle cleat assembly 10 in accordance with the invention,that includes a cap 22. The cap overlays the second plate 20. The cap issized to project slightly above the exposed surface of the second plate,and the exposed edges of the cap are rounded. The second plate therebyis slightly recessed from the cap, such that only the cap engages theground when the user walks about. Preferably, the cap is formed of amolded elastomeric material such as polyurethane, to provide improvedfrictional engagement with the ground and thereby to make walking morecomfortable for the user. In existing cleat assemblies lacking a cap,when the cleat assembly is disengaged from a pedal and the user iswalking about on the ground, the second plate is in direct engagementwith the ground requiring the user to use care when walking about. Thisdirect engagement also has led to undesired wear of the second plate.Additionally, in cleat assemblies having a metallic second plate, theuser must be careful not to scratch the pedal when engaging the cleatassembly to the pedal. In the current embodiment, the cap addressesthese issues. In addition, if the cap becomes unduly worn fromsubstantial walking, it can be readily replaced. The cap's rounded shapealso improves the cleat's aerodynamic properties.

With reference now to FIG. 6 , there is shown the second plate 20 of anembodiment of the clipless bicycle cleat assembly 10 in accordance withthe invention. The second plate includes a body 22 defining a portion ofa first pedal aperture 24, the first pedal aperture being sized andconfigured to receive the clipless bicycle pedal 60 (FIG. 10 ). Thesecond plate also includes a forward flange 26 and rearward flange 28,top surface 30 (FIG. 8D) and a bottom surface 32. The forward flange ofthe second plate includes two spacers 34 each having a central bore 40that extends through the forward flange. Similarly, the rearward flangeof the second plate includes two spacers 36 each having a central bore40 that extends through the rearward flange. The second plate of theembodiment also includes a side tie 25 defining a portion of thecircumference of the first pedal aperture wherein the circumference ofthe first pedal aperture is fully enclosed. The side tie of theembodiment forms a U-shaped structure wherein the side tie curves awayfrom the plane defined by the second plate's body and in the directionof the first plate (FIG. 7C). The curvature of the side tie is providedto accommodate the shaft 62 of the bicycle pedal 60 (FIG. 10 ) when theclipless bicycle cleat assembly is releasably secured to the bicyclepedal. The side tie serves to increase the rigidity and strength of theclipless bicycle cleat assembly compared to a cleat assembly having apedal aperture the circumference of which is only partially enclosed.

With reference now to FIG. 7 , there is shown the second plate 20 of anembodiment of the clipless bicycle cleat assembly 10 in accordance withthe invention. The second plate's forward and rearward flanges each alsohas an outer edge forming a plurality of vertical grooves 38. A cap 22can be disposed over at least part of the bottom surface of the secondplate. In this embodiment, the cap comprises a molded elastomericmaterial and has a top surface 40 comprising a plurality of tongues 42corresponding to the plurality of vertical grooves 38 formed in theforward and rearward flanges of the second plate.

With reference now to FIGS. 8A-8D, there is shown the second plate 20 ofan embodiment of the clipless bicycle cleat assembly 10 in accordancewith the invention. The top surface 30 of the forward flange 26 formstwo spacers 34. The top surface of the rearward flange 28 forms twospacers 36. As noted above, each of the spacers has a central bore 40extending through the forward and rearward flanges (FIGS. 6A and 6B).Each of the spacers also has a sidewall 44, a base end 45 and a terminalend 46. The sidewalls of each of the spacers of this embodiment aretapered from the base end toward the terminal end. The terminal ends ofthe spacers abut the first plate 12 when the second plate is coupled tothe first plate and, therefore, the length of the second plate's spacersdefine a space between the first plate and the second plate when theclipless bicycle cleat assembly is assembled (FIG. 8C). In the presentembodiment, the intermediate plate 16 is made of plastic. The spacersserve to provide a rigid support to avoid deformation (also known as“creep”) of the intermediate plate when the attachment screws aretightened. The intermediate plate can also serve as a spring housing.Without the spacers, tightening of screws attaching the first plate tothe second plate can deform the intermediate plate and, as a result,restricted free flexing movement of the spring clip 18 that can becontained within the intermediate plate (FIG. 18 ). Restricting the freeflexing movement of the spring clip can make it more difficult to engageor disengage the spring clip to/from the pedal.

With reference now to FIG. 9 , there is shown the second plate 20 andintermediate plate 16 of an embodiment of the clipless bicycle cleatassembly 10 in accordance with the invention. The intermediate plate hasa body 48 generally aligned with the body 22 of the second plate anddefining a second pedal aperture 50 generally aligned with the firstpedal aperture 24 of the second plate, the second pedal aperture 50being sized and configured to receive the clipless bicycle pedal. Theintermediate plate also includes a top surface 52, a bottom surface 54,and forward and rearward flanges 56, 58. The forward and rearwardflanges of the intermediate plate generally align with the forward andrearward flanges 26, 28 of the second plate respectively when the cleatassembly is assembled. The forward and rearward flanges of theintermediate plate each defines two bores 60 sized and configured toreceive the spacers 34, 36 on the second plate's forward flange 26 andrearward flange 28 respectively when the cleat assembly is assembled.The top surface 30 of the forward and rearward flanges of the secondplate abuts the bottom surface of the forward and rearward flanges ofintermediate plate respectively when the cleat assembly is assembled.Having an intermediate layer that extends to at least encompass thespacers on the second plate's flanges serves to increase the stiffnessof the cleat assembly and, as previously discussed, the spacers preventdeformation of the intermediate plate when the attachment screws aretightened. Additionally, at least a portion of the intermediate plate'sbody is thicker than the forward and rearward flanges. Decreasing thethickness of the intermediate plate in the region of the spacers servesto further reduce deformation of the intermediate layer due to appliedclamp force when the attachment screws are tightened. This arrangementalso results in a cleat assembly that is easier to walk in and that ismore aerodynamic.

With reference now to FIG. 10 , there is shown an embodiment of aclipless bicycle pedal 60 with which the cleat assembly can be used.

Although the invention has been described in detail with reference onlyto the presently preferred embodiments, those skilled in the art willappreciate that various modifications can be made without departing fromthe invention. Accordingly, the invention is defined only by thefollowing claims

What is claimed is:
 1. A cleat assembly configured to be releasablysecured to a clipless bicycle pedal, the cleat assembly comprising: afirst plate; a second plate disposed over the first plate, the secondplate defining a fully enclosed first pedal aperture having acircumferential periphery; an intermediate plate disposed between thefirst plate and the second plate; a plurality of spacers configured tobe disposed between the first and second plates, each of the pluralityof spacers having a height to space apart the first and second plates ata predetermined distance when the plurality of spacers are disposedbetween the first and second plates; and at least one screw securing thesecond plate over the intermediate plate to the first plate; wherein thesecond plate comprises a forward flange disposed forwardly of the firstpedal aperture, and a rearward flange disposed rearwardly of the firstpedal aperture; wherein the circumferential periphery of the fullyenclosed first pedal aperture comprises a first portion defining aplane, and a side tie portion curving away from the first portion towardthe first plate; wherein the side tie portion forms a U-shaped structureextending from the plane and separated from the forward and rearwardflanges; wherein at least one of the plurality of spacers has a boreextending therethrough; and wherein the at least one screw extendsthrough the bore of the at least one of the plurality of spacers andapplies an immobilizing force to the intermediate plate, theimmobilizing force being sufficient to inhibit the intermediate platefrom moving with respect to the first plate.
 2. The cleat assembly ofclaim 1, wherein the plurality of spacers are formed on the secondplate.
 3. The cleat assembly of claim 2, wherein each of the pluralityof spacers comprises a base end, a terminal end, and a side wall thattapers from the base end to the terminal end.
 4. The cleat assembly ofclaim 3, wherein each of the forward flange and the first rearwardflange comprises at least one opening in communication with the bore ofat least one of the plurality of spacers.
 5. The cleat assembly of claim4, wherein the intermediate plate comprises: a body; and a flangedisposed around at least a portion of the body; wherein the body definesa second pedal aperture; and wherein the flange of the intermediateplate comprises at least one bore sized and configured to allow at leastone of the plurality of spacers to pass through.
 6. The cleat assemblyof claim 5, wherein at least a portion of the body of the intermediateplate is thicker than the flange of the intermediate plate.
 7. The cleatassembly of claim 1, further comprising a cap defining a third pedalaperture generally aligned with the first pedal aperture, the capdisposed over at least a portion of the second plate.
 8. The cleatassembly of claim 1, wherein each of the plurality of spacers comprisesan uninterrupted side wall that surrounds the bore.
 9. A cleat assemblyconfigured to be releasably secured to a clipless bicycle pedal, thecleat assembly comprising: a first plate; a second plate disposed overthe first plate, the second plate defining a fully enclosed first pedalaperture having a circumferential periphery, the circumferentialperiphery comprising a first portion defining a plane, and a side tieportion curving away from the first portion toward the first plate,wherein the side tie portion imparts rigidity to the second plate; anintermediate plate disposed between the first plate and the secondplate; a plurality of spacers formed on the second plate and disposedbetween the first and second plates, each of the plurality of spacershaving a height to space apart the first and second plates at apredetermined distance; and at least one screw securing the second plateover the intermediate plate to the first plate; wherein the second platecomprises a forward flange disposed forwardly of the first pedalaperture, and a rearward flange disposed rearwardly of the first pedalaperture; wherein the side tie portion forms a U-shaped structureextending from the plane and separated from the forward and rearwardflanges; wherein at least one of the plurality of spacers has a boreextending therethrough; and wherein the at least one screw extendsthrough the bore of the at least one of the plurality of spacers andapplies an immobilizing force to the intermediate plate, theimmobilizing force being sufficient to inhibit the intermediate platefrom moving with respect to the first plate.
 10. The cleat assembly ofclaim 9, wherein the side tie portion is offset from the plane.
 11. Thecleat assembly of claim 10, wherein the first portion is in greaterspaced relation to the first plate than the side tie portion.
 12. Thecleat assembly of claim 11, wherein the intermediate plate comprises: abody; and a first flange disposed around at least a portion of the body,wherein a thickness of at least a portion of the body of theintermediate plate is greater than a thickness of the first flange ofthe intermediate plate.
 13. The cleat assembly of claim 12, wherein:each of the plurality of spacers comprises a base end, a terminal end,and a side wall that tapers from the base end to the terminal end; andfor each of the at least one of the plurality of spacers having a boreextending therethrough, the bore extends through the base and terminalends.
 14. The cleat assembly of claim 13, wherein: each of the forwardflange and the rearward flange comprises at least one opening incommunication with the bore of at least one of the plurality of spacersto receive the at least one screw for securing the second plate over theintermediate plate to the first plate; and the first flange of theintermediate plate comprises at least one bore sized and configured toallow at least one of the plurality of spacers to pass through.
 15. Thecleat assembly of claim 9, further comprising a cap defining a thirdpedal aperture generally aligned with the first pedal aperture, the capdisposed at least a portion of the second plate.
 16. The cleat assemblyof claim 9, wherein each of the plurality of spacers comprises anuninterrupted side wall that surrounds the bore.